Composite and metal component production, forming and bonding system

Abstract

A system for producing composite or bonded metal components including: first and second pressure chambers, each pressure chamber having an elastically deformable chamber wall; means for circulating fluid at an elevated temperature and pressure through each said pressure chamber; and at least one mould assembly including at least one separate mould section providing a mould cavity within which a composite or bonded metal lay-up can be located; wherein when the system is in use, the pressure chambers are held together with the elastically deformable chamber walls located in opposing relation, the at least one mould assembly containing a said lay-up being accomodated between the chamber walls while fluid at elevated temperature and pressure is circulated through each pressure chamber such that the lay-up can be compressed and cured or formed.

1. A system for producing composite or bonded metal components including:
 first and second pressure chambers, each pressure chamber having an elastically deformable chamber wall; 
 means for circulating fluid at an elevated temperature and pressure through each said pressure chamber; and 
 at least one mould assembly including at least one separate mould section providing a mould cavity within which a composite or bonded metal lay-up can be located; 
 wherein when the system is in use, the pressure chambers are held together with the elastically deformable chamber walls located in opposing relation, the at least one mould assembly containing the lay-up being accommodated between the chamber walls while fluid at elevated temperature and pressure is circulated through each pressure chamber such that the lay-up can be compressed and cured or formed. 
 
   
   
     2. A system according to  claim 1 , wherein each pressure chamber includes a housing supporting a said elastically deformable chamber wall on a side thereof. 
   
   
     3. A system according to  claim 1 , wherein each pressure chamber includes an outer support frame supporting a flexible bladder therein, one face of the bladder providing the elastically deformable chamber wall for the pressure chamber. 
   
   
     4. A system according to  claim 1 , wherein the mould assembly includes a single mould section for supporting the lay-up. 
   
   
     5. A system according to  claim 1 , wherein the mould assembly includes a pair of said mould sections, the lay-up being located therebetween. 
   
   
     6. A method of producing composite or bonded metal components including:
 locating a composite or bonded metal lay-up in a mould cavity of a mould assembly; 
 locating the mould assembly together with the lay-up between first and second pressure chambers, each pressure chamber having an elastically deformable chamber wall, the chamber walls being located in opposing relation with the mould assembly located therebetween; and 
 circulating a fluid at an elevated pressure and temperature though each pressure chamber such that the composite or bonded metal lay-up is compressed and cured or formed. 
 
   
   
     7. A method according to  claim 6 , including circulating the fluid through each pressure chamber at substantially the same pressure. 
   
   
     8. A method according to  claim 6 , wherein a single mould section is used, including locating a vacuum bag over the mould section to apply an initial compression of the lay-up therein. 
   
   
     9. A system for producing composite or bonded metal components including:
 first and second pressure chambers, each pressure chamber having an elastically deformable chamber wall; 
 at least one mould assembly including a mould section having opposing faces, one of said mould section faces providing a mould cavity within which a composite or bonded metal lay-up can be located, the at least one mould assembly further including a fluid flow chamber being provided adjacent an opposing said mould section face such that fluid circulated through the fluid flow chamber is in direct contact with at least a substantial portion of the opposing mould section face; and 
 means for circulating fluid at an elevated temperature and pressure through each said pressure chamber and through the fluid flow chamber; 
 wherein when the system is in use, the pressure chambers are held together with the elastically deformable chamber walls located in opposing relation, the at least one mould assembly containing the lay-up being accommodated between the chamber walls while fluid at elevated temperature and pressure is circulated through each pressure chamber and the fluid flow chamber of the at least one mould assembly such that the lay-up can be compressed and cured or formed. 
 
   
   
     10. A system according to  claim 9 , further including a top flow control chamber locatable over the mould cavity when the mould assembly is located between the pressure chambers, wherein when the system is in use, fluid at elevated temperature and pressure is circulated through the top fluid flow chamber. 
   
   
     11. A system according to  claim 10 , wherein the top fluid flow chamber includes a bladder formed of elastically deformable material, a face of the bladder being configured to at least generally follow the shape of the mould cavity when the fluid is circulated therethrough. 
   
   
     12. A method of producing composite or bonded metal components including:
 locating a composite or bonded metal lay-up in a mould cavity of a mould assembly including a mould section, the mould section including a face opposing the mould cavity, 
 with a fluid flow chamber being located adjacent said opposing mould section face; 
 locating the mould section together with the lay-up between the first and second pressure chambers, each pressure chamber having an elastically deformable chamber wall, the chamber walls being located in opposing relations with the mould sections with said lay-up located therebetween, and 
 circulating fluid at an elevated temperature and pressure through each pressure chamber and the fluid flow chamber such that the composite or bonded metal lay-up is compressed and cured or formed. 
 
   
   
     13. A method according to  claim 12 , including cycling the fluid temperature through the fluid flow chamber while maintaining a relatively constant fluid temperature within the pressure chambers. 
   
   
     14. A method according to  claim 12 , further including locating a top fluid flow chamber over the mould cavity, and circulating fluid at an elevated temperature and pressure through the top fluid chamber. 
   
   
     15. A method according to  claim 14 , including cycling the fluid temperature within the top fluid flow chamber. 
   
   
     16. A system for producing a composite or bonded metal components including:
 first and second pressure chambers, each chamber having an elastically deformable chamber wall; 
 means for circulating fluid at an elevated temperature and pressure through each said pressure chamber; and 
 at least one mould assembly including a mould section providing a mould cavity within which a composite or bonded metal lay-up can be located, 
 location means for locating the at least one mould assembly in a fixed position, the pressure chamber being supported about the at least one mould assembly in a floating relation relative thereto; 
 wherein when the system is in use, the pressure chambers are held together with the elastically deformable walls located in opposing relation, the at least one mould assembly containing said lay-up being accommodated between the chamber walls while fluid at elevated temperature and pressure is circulated through each pressure chamber such that the lay-up can be compressed and cured or formed. 
 
   
   
     17. A system according to  claim 16 , wherein the location means is in the form of a support frame including support members extending therefrom for supporting the mould assembly, the support members extending through at least one of said pressure chambers. 
   
   
     18. A method of producing composite or bonded metal components including:
 locating a composite or bonded metal lay-up in the mould cavity of a mould assembly; 
 locating the mould assembly together with the composite or bonded metal lay-up between first and second pressure chambers at least substantially filled with fluid, each pressure chamber having an elastically deformable chamber wall, the chamber walls being located in opposing relation with the mould assembly located therebetween; 
 supplying resin to the mould assembly and through the lay-up located therein; collecting the overflow of resin from the mould assembly for subsequent supply to another mould assembly; and 
 circulating fluid at an elevated pressure and temperature through each pressure chamber such that the lay-up is compressed and cured or formed. 
 
   
   
     19. A method according to  claim 18 , including sequentially collecting and supplying said overflow of resin to one or more further mould assemblies. 
   
   
     20. A method according to  claim 18 , wherein the mould assembly is positioned in an inclined position. 
   
   
     21. A method for producing composite or bonded metal components including:
 preparing and locating a composite or bonded metal lay-up in the mould cavity of a plurality of mould assemblies; 
 locating one or more mould assemblies between two separated pressure chambers, each pressure chamber having an elastically deformable chamber wall, bringing the pressure chambers together in a production stage such that the or each mould assembly is located between the chamber walls of the pressure chambers; 
 circulating fluid at elevated temperature and pressure through each pressure chamber during said production stage to thereby compress and cure or form the component; 
 removing the or each mould assembly from between the pressure chambers; and 
 replacing the or each-mould assembly with a further one or more mould assembly accommodating a lay-up for a following production stage. 
 
   
   
     22. A method according to  claim 21 , wherein the circulating fluid is supplied by a fluid circulation system including a plurality of fluid reservoirs respectively containing fluid at differing temperatures, each fluid reservoir being provided with a separate ring means to enable fluid from each said reservoir to be supplied to a plurality of stations, and fluid supply means at each station for supplying fluid from each ring means to a said pressure chamber located at the station. 
   
   
     23. A mould section of a mould assembly for a production system according to  claim 1 , wherein the mould section includes an inner mould skin for providing a mould cavity, an opposing outer mould skin, and a plurality of reinforcement fins interconnecting said inner and outer mould skins, wherein fluid can be circulated through the mould section.